Trailer flooring with hotmelt coating

ABSTRACT

A method for providing improved moisture protection to a wood board flooring comprising a plurality of solid wood components which together form the wood board, such that the wood board has a first surface and a second surface, the method comprising: applying a coating to at least one of the first and second surfaces of the wood board, the coating being substantially free of water and solvents.

RELATED APPLICATION

This application is a Divisional Application of U.S. patent applicationSer. No. 10/932,519, filed on Sep. 2, 2004, which claims priority ofU.S. Provisional Application No. 60/500,195, filed Sep. 4, 2003, both ofwhich are incorporated herein by reference in their entireties.

BACKGROUND

1. Field of the Disclosure

The present disclosure relates to an improved laminated wood flooringfor truck trailers and containers. More particularly, the wood flooringis coated with a hotmelt coating to impart superior protection to theflooring. The use of a hotmelt coating allows the production of improvedflooring at high manufacturing speed, low-cost and without environmentalissues.

2. Discussion of the Background Art

Conventional wood flooring for over-the-road closed van trailers, truckbodies and containers is normally manufactured with hardwoods, such asoak, maple, birch, beech, ash, etc. The green lumber used as a startingmaterial in such manufacture is suitably dried in special dryingchambers under controlled conditions. The dried lumber is then sawedinto strips of rectangular cross-section and defective portions areeliminated by cross cutting the strips. During the cross-cuttingprocess, “hooks” are formed at the ends of the lumber strips.Alternatively, other shapes such as fingers, bevel, etc., may beincorporated at the strip ends. These shapes are primarily designed toform a connection or joint between ends of strips. The relativelydefect-free lumber strips are coated on their vertical sides or edgeswith an adhesive such as urea-melamine formaldehyde or polyvinylacetate. The glue coated lumber strips are then assembled on a conveyorby placing them side to side and behind other strips, which werepreviously assembled. The adhesive is cured by applying heat andpressure to large sections of the assembled lumber strips thus forming aunitary panel. During the assembly of the lumber strips, “strip-endjoints” are formed at each end of every strip with hook, finger or bevelends. These joints are simple mechanical couplings with no significantadhesive bonding. Often times, due to imperfect assembly, a readilyvisible gap is formed at these strip-end joints, which can be seen fromthe top and bottom surfaces of the completed laminated wood floor.

The glued laminated wood is cut to a desired length (up to about 60feet) and width (about 6 to 18 inches) to form floorboards. Most boardsare 10 to 13 inches wide, and 43 to 53 feet in length. The boards arethen planed to a desired thickness and shiplaps and crusher beads aremachined at the longitudinal edges. A shiplap is a rectangularprojecting lip running along the length at an edge of a floorboard.Typically, the lip extends along the width of a board by about ⅜″ to ½″and has about half the thickness of the board. A “top shiplap” has thelip extending from the top half thickness of the board. Similarly, a“bottom shiplap” has the lip at the bottom half of the board. Thecrusher bead is a small semi-circular projection running along thelength on each edge of a board and placed over or below a lip. When thefloorboards are assembled in a trailer such that the side edges ofcorresponding boards are squeezed together, the top and bottom shiplapsof adjacent boards overlap to form a seam at a board or shiplap joint.The shiplap joint between adjacent boards helps to transfer some of theload from one board to its adjacent board. The board joint also helps toprevent the entry of road debris and water into the trailer. The crusherbeads provide spacing between adjacent boards and help in preventingbuckling of the boards due to expansion on absorption of moisture. Awood putty is applied at the strip-end joints on the top and bottomsurfaces of the boards to fill any resident gaps. Finally, the undersideand lateral sides of the floor boards are coated with a water-basedlatex polymeric coating, which is generally referred to as“undercoating” or “board coating” to provide moisture protection. Thecoating is usually applied by spraying. The finished floorboards arepackaged as kits, by stacking one board on top of another, with abouteight boards per kit for installation in trailers. Normally, a kitconsists of two boards with special edge profiles so that they will fitalong the road and curb sides of a trailer. The other boards may beidentical in design and they are placed between the road and curb sideboards. All the boards are supported by thin-walled cross-members of I,C or hat sections, each having an upper flange, which span the width ofthe trailer and are regularly spaced along the length of the trailer.Each floor board is secured to the cross-members by screws extendingthrough the thicknesses of the board and the upper flanges of thecross-members.

Hardwood-based laminated wood flooring is popularly used in trucktrailers since it offers many advantages. The surface characteristics ofhardwoods such as high wear resistance and traction are most desirable.The strength and stiffness of the flooring is important for efficientand safe transfer of the applied loads to the cross-members of thetrailer. The shock resistance of wood is useful to withstand any suddendropping of heavy cargo on the floor. Nail holding capability andability to absorb small amounts of water, oil or grease withoutsignificantly affecting traction are yet additional favorable propertiesof hardwood flooring.

Although the conventional hardwood flooring has many desirable features,it also suffers from certain disadvantages. For example, water from theroads is known to leak into trailers through the gaps of the strip-endjoints that exist in the flooring. The reasons for the water leaks arebelieved to be the capillary action of the gaps and the tendency of theend grain of wood to absorb water. Although the undercoating is supposedto provide a barrier to the path of water, it may not properly coverlarger gaps thus exposing them to moisture. Further, water based latexcoating is significantly permeable to water. Wetting and drying cyclescan degrade the water based undercoating leading to its cracking andpeeling away from the wood. Wood expands on absorption of moisture andshrinks on drying. Continual cycles of expansion and shrinkage of boardslead to delamination of wood strips of the floor.

To alleviate the above-mentioned problems, a fiber reinforced compositewood flooring was designed, tested and refined to be an improvement overconventional wood flooring (U.S. Pat. Nos. 5,928,735; 6,183,824; and6,179,942). This composite wood flooring consists of conventionallaminated wood floorboards with an underlay of fiber reinforced plastic(FRP). The FRP layer is continuously bonded to the underside of eachfloorboard. The top surface of the composite wood flooring isessentially the same as that of the conventional wood flooring. Sincethe FRP is impervious to the passage of water, it completely seals thebottom of the floorboards and solves the problem of leaky strip-endjoints. The fiber reinforcement improves the mechanical properties ofthe flooring and therefore the thickness of the laminated wood can bereduced. However, this approach leads to a product that is much morecostly than undercoated flooring.

Alternatively, it is possible to bond a water impervious layer (U.S.Pat. Nos. 6,558,765 and 6,555,766) such as a un-filled plastic sheet orfilm, filled plastic, recycled plastic, parchment paper, sheet metal,melamine laminate, etc., to protect the bottom surface of floor boards.The plastic can be polyethylene, polypropylene, PVC, polyurethane, ABS,PET, PBT, etc. An adhesive including a reactive hotmelt adhesive is wellsuited to bond these water impervious layers to wood floorboards.However, the use of a water impervious layer can add significant cost tothe product, making it more expensive than undercoated flooring.Further, the process of bonding a separate layer to floorboards istechnically more sophisticated compared to the spraying of undercoating.The bonding process requires much more expensive machinery and controls.This has been successfully done to manufacture composite wood flooringusing FRP for trailers and therefore other substrates can be easilysubstituted for the FRP (U.S. Pat. No. 6,601,357). However, this is nota low cost approach to improve water resistance of flooring.

Berube, U.S. Pat. No. 6,318,794, deals with a composite floor with fiberreinforcement at the bottom side and a polyurethane coating envelopingthe entire outer surface of the floorboard. This patent also discloses afloorboard with anti-slip polyurethane coating with granular constituenton the top side of board. Polyurethane coatings and even epoxy basedcoatings have been used in the transportation industry for a long timeas floor restorers. Essentially, leaks in the flooring of a trailer,which is in service are sealed by applying liquid polymer coatings onthe topside of flooring. In these examples, the use of polyurethane andIsocyanate not only involves high cost for these materials, but alsotakes considerable time to cure the material by cross-linking chemicalreaction to form a protective coating. The faster curing polyurethanecoating such as UV-coatings are very expensive and cannot be applied asthick coatings or with coloring agents, due to limitations of UV-curing.These materials also pose chemical hazards and need to be handled withtremendous care. As such, these coatings are not used by the trailerflooring producers.

Technologists are constantly trying to find ways to improve moistureresistance of wood flooring. Fouquet, U.S. Pat. No. 5,143,418, describesthe use of composite plywood panels as flooring in open platformtrailers. The plywood was composed of veneers of wood with a majority ofthe veneers oriented with the wood grain along the longitudinaldirection while the remaining veneers were oriented with the wood grainalong the perpendicular direction. The top and bottom surfaces of theplywood panels were overlaid with resin impregnated cellulose sheets forproviding moisture and slip resistance. Plywood based flooring is notused in van trailers due to severe structural load conditions arisingfrom the use of lift trucks to move cargo in and out of van trailers.Further, plywood is generally not available in lengths up to 53 feet,which is preferred for trailer flooring.

Scharpf (U.S. Pat. No. 5,509,715) attempts to provide water protectionto laminated wood flooring with a film such as the commerciallyavailable Tyvek that is impermeable to water, but permeable to watervapor. The film is discontinuously bonded to the underside of laminatedwood boards, so that wood is able to release water vapor through thefilm, if the floor gets wet. In practice, water protection of theflooring from the underside is present as long as the discontinuouslybonded film is not damaged by impacting gravel, rocks and road debris.Sometimes condensate water or other water from leaks in the trailer roofor open doors during rain can wet the top side of the floor. This watercan enter the gaps of the hook joints or between boards and becometrapped by the discontinuously bonded Tyvek undercovering. Over time,such trapped water leads to warping of the wood boards and breaking offloor screws. Therefore, this product has been discontinued by theindustry.

Other techniques have been tried by the industry to eliminate watermigration through the flooring from the underside. In one such attempt,a large sheet of plastic film was laid between the cross-members andfloorboards. The film was wrapped around and stapled to the edges of theroad-side and curb-side boards of the trailer. The film was notadhesively bonded to the boards. During road service of trailers withthis type of flooring protection, water was found to enter the spacesbetween the bottom of the boards and the film. Water could come throughthe tiny openings around the floor screws. Alternatively, water couldalso enter from the top side of the flooring from leaks in the roof orfrom the doors being open in wet weather conditions. The trapped waterwas absorbed by the bottom side of the floorboards leading to swelling,expansion and warping. Due to these performance issues, this productdesign was also discontinued by the industry.

The goal of the present disclosure is to improve moisture protection ofthe bottom side of laminated floorboards at comparable cost relative toconventional water-based latex undercoating. Improved moistureprotection in this case means that transfer of water in to the wood ofthe flooring from the bottom side, which side is exposed to road spray,would be significantly lower than that of undercoated flooring. Anotherobjective of the disclosure is the method of manufacturing of themoisture resistant flooring should be as good or better than that of theundercoated flooring in terms of rate of production, simplicity ofoperation and ability to handle large volumes.

Conventional undercoated wood flooring with undercoating on the bottomside and exposed wood top side are not suitable for use in open platformtrailers. This is because the wood top side of flooring is exposed tothe environment. The glue bonds of the wood components tend to breakdown over time when exposed to uv-radiation and moisture. Wood itselfwill discolor and weaken from such exposure. Due to moisture relatedproblems, conventional laminated flooring is also not washed with watereven when used in closed van trailers. Washing of the flooring is usefulafter transporting certain products like nursery items, agriculturalgoods and some chemicals, especially, when a spill occurs. For this typeof application, it is preferable to use wood flooring with greaterdegree of moisture protection on the top side.

The present disclosure does not require a costly water impervious layer,such as a plastic layer or FRP to impart moisture protection tofloorboards or wood board flooring. It is also not based on conventionalcoatings, such as epoxy or polyurethane, that are applied as a 1-part or2-part liquid at ambient temperature, allowed to penetrate the wood andjoints and cured to form a hard surface. Further, the present disclosuredoes not use a conventional water-based or solvent-based polymercoating.

Conventional water-based latex undercoatings are simple to apply, buthave several disadvantages. They do not usually bridge the gaps at thestrip-end joints of the board. The coating is also not impervious towater spray from the roads. Since water can transfer in to the woodthrough the coating, the glue bonds between wood components of flooringcan be affected over the life of the floor. The complete drying ofwater-based undercoating is important to prevent blocking or stickingtogether of the undercoated boards after these boards are stacked andbanded together for shipping. Incomplete drying can lead to transfer ofcoating from the underside of one floorboard to the top face side ofanother board in contact with the coated side in a stack of boards. Suchtransfer of coating can not only lead to blocking, but also contaminatethe top wood side of flooring.

SUMMARY

According to the present disclosure, a virtually 100% solids coatingmaterial in a molten stage is applied on the floorboards or wood boardflooring at high production speed. It is allowed to set or harden bycooling in less than five minutes or even in a few seconds. The 100%solids coating has substantially no water or solvents. The coating canbe thermoplastic or thermosetting in nature. In the preferredembodiment, the coating is a hotmelt. The hotmelt coating is a polymericcomposition, which is a solid at ambient temperature, but it softens andflows on heating so that it can be applied by roller coaters or slot-diecoaters and hardens on the substrate up on cooling. This material doesnot need to loose water or solvents and does not need to undergochemical reactions to set or be dry to touch. It does not need aseparate layer of adhesive such as those used to bond a water imperviouslayer. It can continue to be a thermoplastic material even afterapplication on floorboards. Alternatively, the hotmelt can also exhibitthermoplastic properties during application stage and then undergo areaction with atmospheric moisture to form a thermosetting material. Areactive hotmelt is an example of such a coating that exhibits boththermoplastic and thermosetting properties at different stages. In oneembodiment, the hotmelt is a non-reactive thermoplastic material. Thecomposition of the coating can include one or more of differentcomponents from the categories of polymer, copolymer, binder, resin(tackifier and adhesion promoter), wax, elastomer, rubber, asphalt,filler, coloring agent, anti-oxidants and other additives. Polymers canbe EVA (ethylene-vinyl acetate), polyamide, polyethylene, polypropylene,PVC (polyvinylchloride), polyurethane, etc. In a preferred embodiment,the polymer is a low cost material such as an EVA, polyethylene,polypropylene and PVC. It may also contain other additives to increaseor lower viscosity, to promote hardness, to enhance adhesion to wood, toretard permeation of water, to increase resistance to salt water, toincrease toughness and to prevent blocking.

In one embodiment, the hotmelt coating is applied on the bottom side oflaminated floorboards, while the top side is uncoated. This type offlooring is suitable for most van-trailers, truck bodies and containers.If flooring needs moisture protection on the top side for washing, thetop side of the flooring is coated with the hotmelt. For open platformtrailers, hotmelt coating is applied at least on the top side of thefloorboards and preferably on both the top and bottom sides.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a van trailer showing wood flooringinstalled on cross-members with an I-section.

FIG. 2 is a longitudinal sectional view of a wood floorboard fastened tocross-members of an I-section.

FIG. 3 is the end view of the shiplap assembly of two adjacent woodfloor boards on an I-beam cross-member.

FIG. 4 a is a perspective view of laminated wood with several randomlyarranged hook joints.

FIG. 4 b is a perspective view of two opposing hooked ends of lumberstrips.

FIG. 4 c is a perspective view of a perfect hook joint with little or nogap at the top and bottom sides. FIG. 4 d is a perspective view of animperfect hook joint with a significant gap.

FIG. 5 is a perspective view of a conventional undercoated floorboard.

FIG. 6 is a perspective view of a hotmelt coated floorboard.

FIGS. 7 a and 7 b are sectional views of a hotmelt coated floorboardwith different edge profiles.

FIG. 8 a shows a lap joint.

FIG. 8 b shows a finger joint.

FIG. 8 c. shows a butt joint.

FIG. 8 d. shows a scarf joint.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Conventional wood flooring 11 for over-the-road truck trailers 12 suchas that shown in FIG. 1 is normally manufactured with hardwoods such asash, aspen, elm, yellow-poplar, and preferably oak, maple, birch, beechand the like, although softwoods such as Douglas fir and spruce could beemployed. The green lumber used as a starting material in suchmanufacture is suitably dried in kilns under controlled conditions. Thedried lumber is then sawed into strips 22 of rectangular cross-sectionand defective portions are eliminated by cross cutting the strips.During the cross-cutting process, “hooks” 24 are formed at the ends ofthe lumber strips (see FIG. 4 b). Hooks are shown as an illustrativeexample. Alternatively, laps, fingers, bevel or other shapes could beformed at the strip ends. The relatively defect-free lumber strips arecoated on their vertical sides or edges 25 with an adhesive such asurea-melamine formaldehyde or polyvinyl acetate. The uncured glue coatedlumber strips are then assembled on a conveyor by placing them side toside and behind other strips, which were previously assembled, thusforming glue lines 23 between adjacent strips 22. The adhesive is curedby applying heat and edge pressure to large sections of the assembledlumber strips thus forming a unitary panel of laminated wood 21 such asthat shown in FIG. 4 a. During the assembly of the lumber strips,“strip-end joints” 17 are formed at each end of every strip (see FIG. 4c). These joints are simple mechanical couplings with no significantadhesive bonding. Often times, due to imperfect assembly, a readilyvisible gap 26 is formed at the strip-end joints, which can be seen fromthe top and bottom surfaces of the completed laminated wood floor (seeFIG. 4 d). If required, each hook joint at the ends of the lumber stripsis substituted with a lap joint 30 or a finger joint 31 or a butt joint32 or a scarf joint 33 as illustrated in FIGS. 8 a to 8 d.

The cured laminated wood 21 is cut to a desired length (up to about 60feet) and width (about 6 to 18 inches) and then machined to form severallaminated wood boards 16 (see FIG. 5). Each laminated wood board 16 isplaned to a desired thickness and shiplaps 18 and crusher beads 19 aremachined on its sides. A shiplap 18 has a right-angled step with asquare corner 20 formed by a rectangular projecting lip running alongthe length on each side of a floor board. The crusher bead 19 is a smallsemi-circular or another kind of projection running along the length oneach side of a board and placed above or below a shiplap 18. When thefloor boards are assembled in a trailer such that the side edges ofcorresponding boards are squeezed together, the shiplaps 18 of adjacentboards overlap to form a seam (See FIG. 3). The bead 19 provides spacingbetween adjacent boards and helps in preventing crushing and warping ofthe boards when they expand on absorbing moisture. A wood putty isapplied at the hook joints 17 on the top and bottom surfaces of theboards to fill any resident gaps. Alternatively, the wood putty may becontinuously coated over the top and bottom surfaces of the board whilealso filling the gaps of the hook joints. Finally, the underside andlateral sides including the shiplaps of the floor boards are coated byspraying a water based latex polymeric coating material termed as“undercoating” or ‘board coating” 27 (FIG. 5) to provide moistureprotection. The finished floor boards are assembled into a kit of abouteight boards for installation in trailers. Normally, a kit consists oftwo boards with special edge profiles so that they will fit along theroad and curb sides 15, which are usually metallic components of thetrailer 12. The other boards may be identical in design and they areplaced between the road and curb side boards. A shiplap joint is formedbetween adjacent boards as shown in FIG. 3. In some trailers, a metalliccomponent such as a hat-channel may be placed between any two adjacentboards. The metallic component becomes part of the floor area. Theboards adjacent to the hat-channel have edge profiles designed to matewith the flanges of the hat-channel. All the boards are supported bythin-walled cross-members 14 of I, C or hat sections, each having anupper flange, which span the width of the trailer and are spaced alongthe length of the trailer. Each floor board is secured to thecross-members by screws 13 extending through the thickness of the boardand the flanges of the cross-members (See FIGS. 1-3).

The water based latex undercoating is generally applied on the boards byspraying. This undercoating has a viscosity less than 2000 cps. Thesolids content of the coating is about 30% to 40%. The remainingnon-solid part of the coating is water. The coating is designed forspraying on boards. The use of this type of coating is a standardpractice in the trailer flooring industry in North America. This is dueto environmental issues related to the use of solvent-based coatings andother coatings based on hazardous chemicals such as polyurethane,isocyanate and epoxy. Another reason for using water-based coating isthe low cost of this coating compared to all other available coatings.

To apply the water-based latex undercoating on the floorboards, theplaned floorboards are passed on a conveyor through a spray booth atspeeds of about 70 to 100 feet per minute with the bottom side of boardfacing up. About 6 to 10 mils (wet) of undercoating is sprayed on theboard. The undercoating covers the bottom side and most parts of thelongitudinal edges or shiplaps of the board. The wet coating is dried byevaporating the water for about 5 to 10 minutes in heated tunnels and/orwith the aid of hot air blowers. Upon drying, the coating film thicknessis between 2 to 4 mils.

The hotmelt coated floor board 28 improves the above describedconstruction of conventional undercoated floor board 16 by significantlyimproving moisture protection of the floor board with a fast-setting,low-cost and environmentally friendly coating 29 (as representativelyshown in FIG. 6). In this disclosure, a virtually 100% solids coatingmaterial in a molten stage is applied on the floorboards at highproduction speed of 70 to 100 feet per minute. It is allowed to set orharden by cooling in less than five minutes or even in a few seconds.The 100% solids coating has substantially no water or solvents. Thecoating can be thermoplastic or thermosetting in nature. In thepreferred embodiment, the coating is a hotmelt. The hotmelt is apolymeric composition, which is a solid at ambient temperature, but itsoftens and flows on heating so that it can be applied by roller coatersor slot-die coaters and hardens on the substrate up on cooling. Thismaterial does not need to loose water or solvents and does not need toundergo chemical reactions to set or be dry to touch. It does not need aseparate layer of adhesive such as those used to bond a water imperviouslayer. It can continue to be a thermoplastic material even afterapplication on floorboards. Alternatively, the hotmelt can also exhibitthermoplastic properties during application stage and then undergo areaction with atmospheric moisture to form a thermosetting material. Areactive hotmelt is an example of such a coating that exhibits boththermoplastic and thermosetting properties at different stages. In oneembodiment, the hotmelt is a non-reactive thermoplastic material. Thecomposition of the coating can include one or more of differentcomponents from the categories of polymer, copolymer, binder, resin(tackifier and adhesion promoter), wax, elastomer, rubber, asphalt,filler, coloring agent, anti-oxidants and other additives. Polymers canbe EVA (ethylene-vinyl acetate), polyamide, polyethylene, polypropylene,PVC, polyurethane, etc. In a preferred embodiment, the polymer is a lowcost material such as an EVA, polyethylene, polypropylene and PVC. Itmay also contain other additives to increase or lower viscosity, topromote hardness, to enhance adhesion to wood, to retard permeation ofwater, to increase resistance to salt water, to increase toughness andto prevent blocking.

In one embodiment, the hotmelt coating is applied on the bottom side oflaminated floorboards, while the topside is uncoated. This type offlooring is suitable for most van-trailers, truck bodies and containers.If flooring needs moisture protection on the topside for washing, thetopside of the flooring is coated with the hotmelt. For open platformtrailers, hotmelt coating is applied at least on the topside of thefloorboards and preferably on both the top and bottom sides.

To manufacture hotmelt coated wood floor boards, the laminated woodboard with shiplaps or other edge profiles is sanded or abraded on oneor both major sides to improve flatness of the board. Alternatively, aknife-planed surface of the wood member can also be used. The board mayhave a few strips of wood, which may be too thin to be fully planed orsanded. There may also be a few knots or defects in a few wood strips ofthe board. One or more hotmelt roller coaters are employed to apply thecoating on the board. The hotmelt is heated to about 200 to 450 degreesF. and pumped to the roller coater. The roller coater is equipped withheated rollers to keep the hotmelt in a tacky, viscous and molten stage.The viscosity of the hotmelt at the application temperature ispreferably in excess of 2000 cps, and more preferably in excess of 5000cps, which is much higher than that of water-based or other liquidsprayable coating. The floorboard is passed through the roller coater ina forward pass, wherein the direction of rotation of the coating roll isunopposed to the direction of translation of the board. About 10 to 50grams of coating is applied in the forward pass per square foot per sideof floorboard. By its nature forward pass coater creates a non-smooth orrough coating texture on the board. To smooth out the coating texture asecond coating pass is made. The second pass can be made through areverse coater, wherein the direction of rotation of the coating roll isopposed to the direction of translation of the board. This leads to asmoother coating surface. Alternatively, a second forward pass coatingcan be used to apply about 4 to 20 grams of hotmelt coating per squarefoot per side. By applying less hotmelt material, a smoother coatingsurface can be formed even in forward pass mode. Additional smootheningrollers can be employed to smooth out the coating texture after onesingle forward pass coating or any combination of forward and reversepasses. The smoothening rollers are heated rollers that spin in theforward or reverse direction compared to the direction of translation ofthe board. The smoothening rollers do not apply any additional hotmeltto the board, but smoothen the coating already applied. One or moresmoothening rollers can be employed to improve smoothness of coating.When a non-slip surface is needed, the coating may not be smoothened byadditional rollers. Depending on the type of use, the floorboard can becoated simultaneously on the topside and the bottom side or simplycoated on one side only. The hotmelt is applied to form a mostlycontinuous coating on the board. However, some spots of the board maynot get coated by the roller coater due to low strips, knots or someother defects in the wood. Any low strips, knots and defects that doesnot get roller coated may be coated later by a separate process with thesame hotmelt or some other coating material. The lateral sides orshiplap areas and ends of boards do not lend themselves to coating withhotmelt in a roller coater. These sides may be coated by water basedlatex or some other sealer by conventional methods of spraying orbrushing. Overspray of conventional coating over the hotmelt coating canalso happen. Such overspray material can be specifically designed tomatch color of hotmelt and also to impart anti-block characteristics.

In an embodiment of this disclosure, a forward pass roller coater isused to apply hotmelt of type A on the board in the forward pass. Asecond reverse pass coater is used to apply hotmelt of type B. Hotmelt Acan be designed for improved adhesion to the board. Hotmelt type B canbe designed for improved non-blocking characteristics and smootherfinish.

In another embodiment of this disclosure, a forward pass roller coateris used to apply hotmelt of type A on the board in the forward pass. Asecond forward pass coater is used to apply hotmelt of type B. Thesurface of the coating is further smoothened with reverse smootheningrollers.

In yet another embodiment of this disclosure, a forward pass rollercoater is used to apply a hotmelt on the board in the forward pass. Thecoating is further smoothened by one or more reverse smootheningrollers.

The effectiveness of the hotmelt coating as a significant improvementover water-based coating was studied with the following experiment.Samples of floorboards of size (6″ L×12″ wide) with hotmelt andwater-based latex coatings were prepared. Two types of hotmelt coatings(I and II) were used in this test. A commercially available water-basedcoating was also used for comparison. The water-based coating wassprayed on the board and allowed to dry for several days. Hotmeltcoating I was applied by combination of forward coating and reversecoating. Hotmelt coating II was applied by combination of forwardcoating and reverse smoothening. Only the bottom side of each sample wascoated with hotmelt. The remaining topside and four lateral edges of thesamples were not coated by hotmelt. The topside and four lateral edgesof all samples were sealed with a 2-part epoxy. Two coats of epoxy wereapplied to ensure a good seal. The samples were then submerged in water.The weight gain (in grams) of the samples was recorded over three days.The average results are shown below.

Absorption of Water (Grams) by Samples of Coated Boards

Water soak duration Sample Type 4 hrs 8 hrs 24 hrs 48 hrs 72 hrsUndercoating 8 11.8 21.5 33.3 42.3 Hotmelt I 2.5 3.8 8.8 16.3 24.5Hotmelt II 2.8 2.8 5.5 8.3 10.5

Undercoated samples absorbed 42.3 grams of water, while hotmelt IIcoated boards absorbed only 10.5 grams of water. From the above test, itis clear that hotmelt coating provides significant improvement inperformance over water-based coating for trailer flooring. Otheradvantages are related to manufacturing of hotmelt-coated floorboards asdiscussed below.

Typical thickness of water-based latex coating after drying is about 2to 4 mils. Hotmelt coating can be easily applied in thickness up to 20mils, if needed. If water-based coating is applied too thick (higherthan 10 wet mils), it takes a very long time (more than 10 minutes) todry the coating. Incomplete drying leads to transfer of coating to anadjacent board upon stacking of these boards. For hotmelt coating, thereis no drying required. The coating simply hardens or sets by cooling.This hardening can happen in less than 30 seconds depending on thehotmelt formulation, coating thickness, etc. In general, hotmelt coatedboards can be processed in a fraction of the time and with less dryingspace compared to water-based latex coated boards.

Water based latex coating costs about 8 $/gallon. At about 40% solidcontent, the cost of the solid part of the coating is about 2 $/lb.Hotmelts are commercially available at a cost as low as 1 $/lb.Therefore, the cost of the hotmelt coating is lower compared towater-based latex coating at equal thickness of dry coating. Hotmeltcoating is preferably applied thicker than the water-based coating (indry mils) for better sealing of the floorboard. This is possible becauseof fast setting of the hotmelt and its lower material cost. Compared tothe hotmelts, conventional liquid coatings based on epoxy andpolyurethane are much more expensive.

When working with water-based coating, the clean up of equipment andworker's hand washing is normally done with water and possibly somesolvents. This type of clean up leads to some unavoidable run-off ofcontaminated water. However, for hotmelt coating, contaminated run-offcan be completely avoided. It is also possible to maintain a much morecleaner factory working environment by using hotmelt coating.

The use of conventional coatings based on liquid 1-part or 2-partpolyurethane, isocyanate and epoxy require the handling of hazardouschemicals. Special permits and testing may be needed before using thesematerials in large volumes to ensure worker safety and environmentalcompliance. In a preferred embodiment, the hotmelt coating of thepresent disclosure does not have such hazardous chemicals.

When using a water impervious layer, an adhesive is required to bond thelayer to wood boards. Further, since the boards have varying widths (10to 13 inches), the layer needs to be matched up in width with the board.This requires additional manufacturing steps and large inventory oflayer of varying widths. In the case of hotmelt coating, the rollercoater used to apply the coating can coat any width of board up to itsmaximum limit. There are no special procedures needed to accommodate theboard width changes. This provides tremendous advantages inmanufacturing, similar to the spraying of water-based latex coating.

While the disclosure has been described herein with reference to thespecific embodiments thereof, it will be appreciated that changes,modification and variations can be made without departing from thespirit and scope of the inventive concept disclosed herein. Accordingly,it is intended to embrace all such changes, modification and variationsthat fall with the spirit and scope of the appended claims.

1. A method for providing improved moisture protection to a wood boardflooring comprising a plurality of solid wood components which togetherform said wood board, such that said wood board has a first surface anda second surface, said method comprising: applying a coating to at leastone of said first and second surfaces of said wood board, said coatingbeing substantially free of water and solvents.
 2. The method accordingto claim 1, wherein said coating contains at least one or more materialsselected from the group consisting of: polymer, copolymer, binder,resin, elastomer, coloring agent, filler and wax.
 3. The methodaccording to claim 2, wherein said polymer is at least one selected fromthe group consisting of: ethylene vinyl acetate, polyethylene,polypropylene, polyvinylchloride and polyamide.
 4. The method accordingto claim 1, wherein said coating is applied to said wood board by one ormore roller coaters.
 5. The method according to claim 1, wherein saidcoating is applied to said wood board by one or more rollers.
 6. Themethod according to claim 1, wherein said board further comprises atleast one longitudinal edge, and further comprising: applying awater-based latex coating to said longitudinal edge.
 7. The methodaccording to claim 1, further comprising: sanding or abrading thesurface of said wood board prior to applying said coating to saidsurface.
 8. The method according to claim 4, wherein said coating is ahotmelt material which is heated to about 200 to 450° F. and pumped tosaid roller coater for application to the surface of said wood board. 9.The method according to claim 4, wherein said roller coater comprisesheated rollers, such that said coating is maintained in a tacky, viscousand/or molten stage prior to being applied to said surface of said woodboard.
 10. The method according to claim 9, wherein said coating has aviscosity of at the application temperature in excess of about 2000 cps.11. The method according to claim 10, wherein said viscosity is inexcess of 5000 cps.
 12. The method according to claim 4, wherein saidwood board is passed through said roller coater in a forward pass,wherein the direction of rotation of the coating roll is unopposed tothe direction of translation of said wood board.
 13. The methodaccording to claim 1, wherein said coating is applied to said wood boardin a weight in the range of between about 10 to 50 grams per square footper surface of said wood board.
 14. The method according to claim 12,further comprising a second coating pass, wherein the direction ofrotation of said coating roll is opposed or unopposed to the directionof translation of said wood board.
 15. The method according to claim 14,wherein said second coating pass applies an additional coating layer tosaid wood board in a thickness in the range of between about 4 to 20grams per square foot per surface of said wood board.
 16. The methodaccording to claim 4, wherein at least one additional step of contactingthe coated wood board by one or more subsequent roller to thereby smoothout the texture of said coating applied to said wood board.
 17. Themethod according to claim 16, wherein said subsequent roller is a heatedroller which spins in either the forward or reverse direction comparedto the direction of translation of said wood board.
 18. The methodaccording to claim 14, wherein said forward pass roller coater applies afirst hotmelt material coating to a surface of said wood board and saidreverse pass coater applies a second hotmelt material coating to saidsurface of said wood board.
 19. The method according to claim 18,wherein said first hotmelt material includes adhesive characteristics.20. The method according to claim 18, wherein said second hotmeltmaterial includes non-blocking characteristics.
 21. The method accordingto claim 1, wherein said coating comprises about 100% solids.
 22. Themethod according to claim 1, wherein said coating is eitherthermoplastic or thermosetting.
 23. The method according to claim 1,wherein said coating is a hotmelt material which is solid at ambienttemperature, but softens and flows upon heating.